The Aluminum Advantage

Commercial Vehicle Applications

Todd SummeTechnical Committee, The Aluminum Association’s

Aluminum Transportation Group

Division Manager, Product Design & Development – Alcoa

www.autoaluminum.org

2

Defining Who We Are

Session CV702

3

Our Mission

• Central resource for the

automotive industry on

aluminum

• Promote research and

programs highlighting

advantages

• Expanding mission to

include commercial

vehicles

www.autoaluminum.orgSession CV702

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Aluminum Builds a Better Vehicle

Reduced Emissions

Mass Reduction

Enhanced Performance Improved Safety

Better Fuel Economy

Infinitely Recyclable

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5

Research Validates Benefits of

Lightweighing

• Safety: Size vs. Weight (DRI 2004)

• Vehicle Structure: Manufacturing

and Lifecycle Cost Analysis (IBIS

2005)

• Improving Sustainability in the

Transport Sector Through Weight

Reduction and the Application of

Aluminum (IAI 2006)

• Benefit Analysis: Use of Aluminum

Structures in Conjunction with

Alternative Powertrain

Technologies in Automobiles (IBIS

2008)

• Aluminum Growth Study (Ducker

2009 & 2006)

1

3

5

7

9

11

13

15

0 5 10 15 20 25

% Weight Reduction

% F

ue

l E

co

no

my

Im

pro

ve

me

nt

Small Car - Resized Engine Mid Size Car - Resized Engine Small SUV - Resized Engine

Large SUV - Resized Engine Truck - Resized Engine Small Car - Baseline Engine

Mid Size Car - Baseline Engine Small SUV - Baseline Engine Large SUV - Baseline Engine

Truck - Baseline Engine

Impact of Vehicle Weight Reduction on Fuel Economy for

Various Vehicle Architectures (Ricardo 2007)

ASSOCIATION SPONSORED RESEARCH

Session CV702

Weight reduction & resizing

10% 6-7%

6

Validation Leads to

Continuous Growth

Source: Ducker 2009

North American Light Vehicle Aluminum

Content Continues to Climb

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Why We Are Here Today

• Apply our auto industry model to the commercial vehicle

industry

• Lightweighting with aluminum can help you tackle the

challenges

• Auto companies and other third-parties acknowledge aluminum’s

value proposition will help them meet 2016 CAFE standards

• Overview

• Industry challenges

• Value proposition

• Weight saving benefits

• Research and data

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Challenges Facing Industry

• Rising energy costs

• Growing concern over

greenhouse gas emissions

• Federal mandates

continue to add weight to

heavy-duty vehicles

• Weak economy

Of the 83 million barrels of crude oil used per day,

trucks account for more than half of the oil used in

transportation and its share is projected to increase

Source: International Energy Outlook 2005; U.S. EIA

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Why Aluminum for Commercial

Vehicles?

THE VALUE PROPOSITION

• Increased payload

• Lower maintenance costs

• Reduced fuel

consumption

• Reduced greenhouse gas

emissions

• Improved durability

• Higher resale value

• Infinitely recyclable

According to the U.S. EPA, a 10% drop in

truck weight reduces fuel use between 5-10%

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Truck Owners See Value in

Lightweighting

Source: Alcoa 2008, Q4 research

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Aluminum Already on the Road

• Cab structure

• Trailer side walls and structure

• Flatbeds/tippers/dump bodies

• Forged aluminum wheels

• Frame cross members

• Coal trucks

• Fifth wheel

• Fuel tanks

• HVAC components

• Landing gear

• Tank bodies

• Bellhousing

The average Class 8 Tractor today

contains 1,000 lbs. of aluminum

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How Much Weight is Being Saved?

Tractor

• Axle hubs = 120 lbs.

• Centrifuse brake drums = 100 lbs.

• Clutch housing = 50 lbs.

• Front axle leaf springs = 70 lbs.

Trailer

• Roof posts = 75 lbs.

• Floor joists = 300 lbs.

• Upright posts = 600 lbs.

• Hubs and wheels = 900 lbs.Aluminum wheels on a tractor can

save 30 lbs. each for a total savings

of 300 lbs.

Source: U.S. EPA Weight Reduction Fact Sheet 2004

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Emerging Technologies Save More

Weight

3,500 lbs. weight savings potential

Save 30 lbs. per

wheel

Cab Rear Wall

Save 49 lbs.

Save 20 lbs.

per door

Frame Rails

Save 435 lbs.

Cab X-Member

Save 38 lbs.

RR Door Surround

Save 150 lbs.

Landing Gear

Save 50 lbs.

Cab Floor

Save 56 lbs.

Slider Box

Save 150 lbs.

Cab Roof

Save 60 lbs.

Side Wall

Save 1,000 lbs.

Rear Door

Save 187 lbs.

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Research Supporting Our

Value Proposition

• Potential Savings as a Result of Weight

Reduction (IFEU Heidelberg 2003)

• Improving Sustainability in the Transport

Sector via Weight Reduction and

Application of Aluminum (IAI 2006)

• Case Study: China Bus Project (Alcoa

2008)

• Impact of Weight on Rolling Resistance

and Fuel Economy (Smithers 2009)

• Simulator Data (Major Tire Manufacturer

2007

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IFEU Heidelberg Research Findings

• Results based on real-

world experience of truck

OEMs

• Weight is a factor in truck

and bus fuel economy

• Trucks and buses

represent a large potential

fuel savings

• Duty cycle dependant

Source: IFEU, SGKV 2002

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Estimated Fuel Economy Benefit

from 10% Weight Reduction

Source: IFEU, SGKV 2002

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Impact More Pronounced in

Urban Setting: Bus Example

Duty cycle is important factor

3. Gradient Resistance

FSt = m. g. sin a

G = m. g.

Source: IFEU, Alcoa

Physical resistances have an impact

on vehicle fuel efficiency and mass of

the vehicle is a significant factor

Impact is more pronounced in urban setting

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China Bus Project: Real World Success

Value – Ecological

• Reduction in CO2 emissions

• Reduced road surface wear

and tear

Value – Financial

• Less fuel

• Maintenance savings (tires,

brakes, suspension)

• Improved corrosion resistance

• Payback of 2-3 years

Weight

Reduction of

1,400 kg (12%)

>6% Fuel

Economy

Improvement

50 Tons of

CO2 Lifetime

Space Frame

Extrusions

Wheel

Body Panel

Source: Alcoa

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Relevant Auto Study: Aluminum Adds

Value to Alternative Powertrains

Source: IBIS Associates

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Aluminum Wheels Pay Fuel Economy

Dividends

An aluminum

wheel can improve

tire rolling

resistance by up to

3% over a

comparable size

steel wheel

Source: Smithers Scientific Services

3% less rolling resistance

=1% fuel savings

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Major Tire Manufacturer

Simulator Data

Source: Major Tire Manufacturer

HTUFRegional

36,312 36,312Base Weight

Drive Cycle

16,340

HTUF

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IAI Transport Model Illustrates Potential

CO2

Savings from Lightweighting

IAI/EAA/AA

Transport

Lifecycle

Model

User Input

Specifications

of vehicles and

components

Customer

scrap

generation

Fuel/electricity

consumption

during use

Vehicle recycling

Industry Inputs

CO2 equivalents

Final energy

Aluminum

production date

Output

Final energy savings

through lightweighting

CO2 equivalent savings thought lighweighting

Carbon footprints of aluminum and competing material

Source: IAI

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IAI: Aluminum Helps Reduce CO2

• Auto aluminum already

saving 300 million

metric tons of CO2

annually

• Including CO2 impact of

aluminum production

• Use-phase savings far

outweigh production

CO2 generation

• Recycled aluminum

uses 95% less energy

Specif ic Savings

(Tons of CO2 per ton of w eight save)

28

1823

3

53

0

10

20

30

40

50

60

Bus -

Urb

an

Bus -

Suburb

an

Tru

ck -

Weig

ht

Constr

ain

ed

Tru

ck -

Volu

me

Constr

ain

ed

Car

3,000-3,500 lbs. 3,500-4,500 lbs. 300-500 lbs.

Potential

Weight

Savings:

Source: IFEU, 2003

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Use-phase Savings Outweigh

Production Energy Generation

Source: Alcoa – Automotive Example

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GJo

ule

s

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Aluminum is a Part of the Solution

More Payload AND Lower Costs

• One ton of weight reduction = up to

588 gallons of diesel per year

• Lower maintenance costs

• Lower tire and brake costs

Higher residual value and durability

• Corrosion resistant parts last longer

Reduced Lifetime CO2 Emissions

• Save 18 tons of CO2 for every ton of

aluminum you add to your fleet

Reduced dependence on imported oil

Infinitely recyclable

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Help US so that we can help YOU

Research topics

Data gaps to fill

Session CV702

The Aluminum Advantage

Commercial Vehicle Applications

Todd SummeTechnical Committee, The Aluminum Association’s

Aluminum Transportation Group

Division Manager, Product Design & Development – Alcoa

www.autoaluminum.org